3-Phase Complete PMA Generator

thingiverse

7/28/2018 - Home from hospital : ) ... Stator windings completed and inserted into one half of housing. Expect to assemble today and initiate some bench testing. New o-scope arrives Monday to conduct in-depth testing. Housing is an extremely tight fit. I managed to insert three sides, then used a screwdriver in one of the housing's four mounting holes to provide leverage for gently prying away. The four mounting bolts for the housing may not even be required. Once inserted, consider applying two coats of clear lacquer on the inside. ADDED TWO ALTERNATE ROTORS FOR LARGER N52 MAGNETS TO INCLUDE: 60 x 10 x 5mm and 2" x 1" x 0.5" (50.8 x 25.4 x 12.7mm) Also added wire retainer strips that tightly fit each stator slot, preventing coil wires from coming loose. I chose to implement a three-phase winding configuration. However, the stator features thirty-six slots, so it's up to you to wind in any manner you prefer depending on your specific application. I've provided an excellent video demonstrating how to wind for three-phase. Cooling: It is highly recommended to place a fan blade on both sides of the housing ... one pushing air in and the other pulling air out. Increased housing height allows plenty of room for windings, and added more cooling vents. GREAT VIDEO ON THREE-PHASE STATOR COIL WINDING TECHNIQUE - https://www.youtube.com/watch?v=TwYUVbg5Jmc 7/11/2018: PMA Frame.stl added. Use two six-millimeter shafts/rods (each two hundred millimeters long) on the two bottom holes of the frame. It also provides support for the housing. 7/6/2018: Updated rotor & housing STL's as ten-millimeter shaft / bearings necessitate larger holes. Received all necessary hardware from Amazon and in process of building now. Magnets fit rotor perfectly! If you wish to use larger magnets (six large N52's would be ideal) just import the rotor into TinkerCAD and modify. For six magnets, rotate them sixty degrees apart. 7/4/2018: Added a new version of the stator core to accept more windings & larger gauge wire. A free-standing frame is ready that utilizes two six-millimeter rods. ASSEMBLY BREAK-DOWN VIDEO - https://www.youtube.com/watch?v=cgKV0p0UAHs&feature=youtu.be Proto-pasta makes 'rustable' filament containing iron. After a while, the iron begins to oxidize. This type of filament could be utilized to increase the permeability of the stator core. RUSTABLE FILAMENT: https://www.amazon.com/Proto-pasta-FEP11705-Rustable-Magnetic-Spool/dp/B07BGR2JFV/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1 BRIDGE RECTIFIER FOR THREE PHASE: https://www.amazon.com/gp/product/B07BGR2JFV/ref=oh_aui_detailpage_o00_s02?ie=UTF8&psc=1